Antimicrobial Batch Dilution System

ABSTRACT

An antimicrobial supply system employs a process water supply and incorporates a metallic ion supply connected to the process water supply to provide a high ion concentrate to an output. A dilution reservoir is connected to the metallic ion supply output and has an input from the process water supply. A pump is connected to an output of the reservoir. A manifold connected to the pump provides a dilute concentrate to at least one washing system and a recirculation loop to the dilution reservoir for enhanced mixing of the dilute concentrate. An electronics control module is connected to a first flow controller between the process water supply and the metallic ion supply and a second flow controller between the metallic ion supply and the reservoir for dilution control establishing a desired metallic ion concentration.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. patent application Ser. No. 15/180,908, filed Jun. 13, 2016, which is a continuation in part of U.S. patent application Ser. No. 14/099,066, filed on Dec. 6, 2013, which is a continuation in part of U.S. patent application Ser. No. 13/968,084, filed on Aug. 15, 2013. The entire contents of the Ser. Nos. 15/180,908, 14/099,066 and 13/968,084 applications are incorporated herein by reference.

BACKGROUND OF THE INVENTION Field

The present invention is in the technical field of antimicrobial treatment. More particularly, the present invention provides a system employing metallic ion generation and dilution in desired concentrations, for batch storage and entrainment in a flow for use in antimicrobial treatment.

Related Art

Shortcomings of existing antimicrobial treatments can lead to the spread of infection through direct contact, airborne disease and waterborne disease. These diseases can be acquired by their victims from contacting contaminated surfaces, breathing air containing pathogens, or drinking pathogen containing water. Contaminated drinking water especially affects populations of second world and third world countries. The lack of inexpensive means to rid drinking water of harmful living microbes results in widespread illness and death in second world and third world countries. Similarly; contamination of fabrics or linens in uniforms, surgical scrubs, sheets, blankets, napkins; table cloths and similar materials by microbial pathogens can contribute to spread of disease.

Previous antimicrobial treatments require concentrated chemicals which are potentially or actually harmful to people and the environment. Such antimicrobial treatments also do not provide a lasting antimicrobial effect after the treatment has been administered. Existing antimicrobial treatments can also lead to immunization of evolved pathogens to the respective treatment. Such immunization of evolved pathogens can result in infections which cannot be treated with the conventional treatments that caused the pathogens to become immune.

Enterprises which specifically have problems with the spread of infectious diseases include, but are not limited to: the cruise line industry, hotel and gaming, professional sports teams, health and fitness clubs, nursing homes, and hospitals. Healthcare facilities currently have a growing problem with immunized pathogens being virtually untreatable with conventional methods. With such hospital infections, the harmful microbes are often carried in the linens and clothing provided by the hospital. Once hospital linens have been laundered and treated, they are susceptible to recontamination by microbes and pathogens. Pathogens carried by these linens can infect hospital patients and even cause death.

It is therefore desirable to provide an antimicrobial treatment system which may be employed directly in water supply systems to provide efficacious antimicrobial action.

SUMMARY OF THE INVENTION

The present invention is a device which releases a lasting, metallic, antimicrobial agent to which no known pathogens can become immune. Embodiments of the antimicrobial device disclosed provide an antimicrobial supply system having a process water supply and incorporating a metallic ion supply connected to the process water supply to provide a high ion concentrate to an output. A dilution reservoir is connected to the metallic ion supply output and has an input from the process water supply. A pump is connected to an output of the reservoir. A manifold connected to the pump provides a dilute concentrate to at least one washing system and a recirculation loop to the dilution reservoir for enhanced mixing of the dilute concentrate. An electronics control module is connected to a first flow controller between the process water supply and the metallic ion supply and a second flow controller between the metallic ion supply and the reservoir for dilution control establishing a desired metallic ion concentration.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reference to the following detailed description of exemplary embodiments when considered in connection with the accompanying drawings wherein:

FIG. 1 is a block diagram of a batch dilution system for metallic ion antimicrobial agent generation, storage and distribution;

FIG. 2 is a system flow diagram of an exemplary embodiment of an electronic control and monitoring system, separate fluid lines, fluid diffusion sub-assembly and antimicrobial canister for metallic ion introduction;

FIG. 3 is a block diagram of a detailed embodiment of a batch dilution system employing antimicrobial canisters for metallic ion introduction;

FIG. 4 is a representation of a second embodiment of a metallic ion supply;

FIG. 5 is a block diagram of a detailed embodiment of a batch dilution system employing the metallic ion supply of FIG. 4; and,

FIG. 6 is a schematic representation of an industrial washing system showing inlet flow from a batch dilution system for use with a Continuous Batch Washer (CBW).

DETAILED DESCRIPTION OF THE INVENTION

The embodiments disclosed herein provide a system for generation and batch dilution of metallic ions for use as an antimicrobial agent in processes such as commercial washing systems. As shown in FIG. 1, the system 5 incorporates a bulk reservoir 10. A feed water source 12, such as a house soft water system in a commercial washing facility, supplies water to a deionizing system 14 and heater 16 producing process water. A flow controller 18 operated under the control of an electronics control module 20 then provides the process water to the bulk reservoir 10. A metallic ion supply 22 adds antimicrobial ions into the process water forming a high ion concentrate for release through a second flow controller 24 to the bulk reservoir 10 for mixing with the process water to yield a desired dilute concentrate with metallic ions for use as an antimicrobial agent. The dilute concentrate is then provided from the reservoir 10 through a pump 26 to a manifold 28 for distribution to the commercial washers or similar systems. Recirculation of dilute concentrate from the manifold 28 to the reservoir 10 allows the reservoir to act as a buffer so that overall demand is equivalent to total mean demand on system, irrespective of spikes in demand (which are only then gated by outlet pumping rate).

FIG. 2 shows a system flow diagram of a first embodiment of the metallic ion supply 22 with a metallic ion supply canister 208 and fluid diffusion device 209, a manual water shut off 217, a water filter 219, water inlet 231, air inlet 232, an antimicrobial fluid combination outlet 233, the electronics module 20, which is a programmable device such as a microprocessor having software or firmware for specific INITIALIZATION; IDLE; PROCESS; and SHUTDOWN sequences, a solenoid water shut off valve 220, a water temperature sensor 221, a water pressure sensor 222, a air pressure sensor 224, a solenoid air shut off valve 226, and a flow sensor 229. The metallic ion supply canister 208 may be configured as disclosed in application Ser. No. 13/968,084.

The electronics module 20 has a power switch 501, manual start button 502, manual stop button 503, cooling fans 504, LCD display 505, and Manual Mode/Automatic Mode switch 506. The electronics module 20 also has wired and/or wireless connection 507 to local area internet networks to send data to any remote monitoring system with an internet connection. This internet capability also allows the system to be controlled wirelessly over the internet. For example, the system can be turned on and off over the internet and the allowable parameters for sensor detection can be adjusted over the internet. Because, the electronics module 20 can be controlled using the various buttons and switches on the electronics module 20 itself, or remotely though a local area network, the operator can control and monitor the present invention on site or offsite. The compilation of the electronics module programs provides the electronic control and monitoring system software. If the electronics module 20 receives electronic communication from one of the sensors, the electronic control and monitoring system software can be programmed to send signals or alerts to the operator via the wireless connection 507 or as messages to the LCD 504. The electronic control and monitoring system software also continuously logs data on system events and on received transmissions from the multiple sensors.

The solenoid water shut off valve 220, is used to start and stop water flow entering through inlet 231 as shown by arrow 508 through the system. The water temperature sensor 221 communicates electronically with the electronics module 20 in order to enable the electronic control and monitoring system software to log data or send an alert to the operator if water temperature deviates from a desired range. The water pressure sensor 222 communicates electronically with the electronics module 20 in order to enable the electronic control and monitoring system software to log data or send an alert to the operator if water pressure deviates from a desired range. The air pressure sensor 224 communicates electronically with the electronics module 20 in order to enable the electronic control and monitoring system software to log data or send an alert to the operator if air pressure deviates from a desired range. The solenoid air shut off 223 is used by the electronics module to start and stop air flow through the system entering at inlet 232 as indicated by arrow 509. The flow sensor 229 determines outlet flow from the system through outlet 233 as shown by arrow 510 and communicates electronically with the electronics module in order to enable the electronic control and monitoring system software to log data or send an alert to the operator if flow rate deviates from a desired range. A water pressure regulator 218, an air pressure regulator 227, and a flow reducer 228 provide additional for the metallic ion supply system.

The antimicrobial canister 208, the diffusion device 209, the manual water shut off 217, and water filter 219 are interconnected by the water line 216 and air line 223. The electronic devices are connected to the electronics module 20 by the electronic wiring 225. The electronic devices, mechanical devices, and the interconnecting plumbing lines and wires shown are all mounted to a mounting surface 215. An example set of parameters for the electronic control and monitoring system software might be programmed to monitor and control are the following: 140° F. water temperature, 15 psi of water pressure, 25 psi of air pressure, 2 gallon per minute (GPM) of flow rate, all with an acceptance range of within +/−15% before alerting the operator via warning and/or error messages displayed on the LCD screen on the electronics module 20 or through alerts transmitted over the local area network connection when the electronic control and monitoring system transmits a status report.

Details of an implementation of the first embodiment of the metallic ion supply for the batch dilution system are shown in FIG. 3. The deionizer 14 employs a granulated activated carbon (GAC) 302 receiving water from the house soft water source 12. Water drawn from the GAC flows through a reverse osmosis (RO) filter 304 and into a deionizing (DI) bath 306 from which process water is provided to the heater 16 through a solenoid valve 308 controlled by the electronic control module 20 acting as one element of the controller 18. A pressure gage 310 is provided for process control. Process water from the heater 16 is then provided to the metallic ion supply 22 as previously described with respect to FIG. 2. For the embodiment of FIG. 3, three canisters 208 a, 208 b and 208 c each with the associated control valves described in FIG. 2 are employed. The canisters may be operated individually or in parallel for delivery of desired concentrations of metallic ions to the reservoir 10. Multiple canisters allow the system to keep up with demand. To achieve desired concentration of antimicrobial metallic ions in a water stream flowing through canisters 208 analysis demonstrates that the fluid combination entrains antimicrobial metallic ions as a log function with respect to uptake time (contact time of the fluid combination with the substrate in the canister), uptake function Y=A ln(x)−B, where Y is the entrained ion concentration in parts per million (ppm) and x is the uptake time (seconds). Use of multiple canisters allows either an increase concentration (followed by dilution in reservoir at higher rate) or a higher total flowrate through the canisters with less bypass dilution as described subsequently, Deionization removes organic and ionic constituents from feed water. These constituents are considered contaminants. With contaminants removed, the equilibrium driving force for silver ion dissolution into the fluid combination increases as a result of the high purity (18 megaohm) of the DI fluid combination. Effectively, the DI fluid combination is a more effective solvent when ionizing/dissolving Ag⁰ (metallic silver) to Ag⁺ (aqueous silver ions), (such is the case with the finely woven metallic silver coated nylon cloth) when compared to city/tap feed water sources. Additionally, controllability and consistency of the system increase with anionic and organic contaminants removed. With reactive anions, such as chloride, removed from feed water via DI, kinetic conditions are consistent regardless of installation site beginning water quality. Anionic oxidants, such as chloride, affect the Ag⁰ to Ag⁺ dissolution process with varying degrees of impact depending on respective concentrations, by affecting the ability of dissolved oxygen to react with the surface of the silver coated nylon cloth or other metal bearing structure in the canister. In the absence of contaminants, the antimicrobial canister releases Ag⁺ dependent upon the fluid combination dissolved oxygen content, temperature, and velocity (according to Reynold's number) and reaction time allowed between the fluid combination and silver coated nylon cloth inside the canister

A dilution bypass 312 activated by solenoid valve 314 acting as a second element of controller 18 connects the process water from the deionizer 14 directly to the dilution reservoir 10. A flow totalizer 316 in the dilution bypass 312 is provided for process control by the electronic control module.

The dilution reservoir is filled and resupplied by activation of the metallic ion supply flowing hot process water from the heater 16 into one or more of the canisters 208 a, 208 b and 208 c to provide high ion concentrate to the reservoir 10. A concentration probe such as a total dissolved solids (TDS) probe 318 (or in alternative embodiments a conductivity probe) measures ion concentration in the reservoir 10 which is provided to the electronics control module 20 and the electronic control module controls bypass solenoid valve 314 to add process water to the reservoir using flow totalizer 316 to achieve a desired dilute concentrate for fluid in the reservoir. A level probe system 320 provides at least a “tank full” level measurement and a “tank empty” measurement to the electronic control module for activation of the fill sequence. One or more intermediate fluid levels in the reservoir may be measured to allow intermediate fill or other process control.

As previously described, circulation pump 26 draws dilute concentrate from the reservoir 10 in a continuous flow loop through the manifold 28 thereby maintaining the mixed condition of the antimicrobial dilute concentrate solution. An adjustable flow meter 322 provides for flow measurement. For the embodiment shown, multiple individual Conventional Washer-Extractors (CWE) 324 a-324 d draw antimicrobial dilute concentrate solution from the manifold through solenoid valves 326 a-326 d as required in their wash cycles.

A second embodiment of the metallic ion supply 22 is shown in FIG. 4. A pelletized metallic supply system 400 incorporates a revolving carousel 402 that supports multiple cartridges 404 containing a metallic or metallic compound powder (compressed/pelletized or loose), for an exemplary embodiment AgNO₃ powder. A rinse head 406 having a nozzle 408 sized to engage the cartridges 404 is connected to the deionizer 14 for process water supply. The carousel 402 aligns a cartridge 404 with the nozzle 408 and process water is sluiced through the cartridge into a capture container 410 providing a dose of high ion concentrate which is connected for flow into the reservoir 10 or alternative flow path through inlet 411.

As shown in FIG. 5, for a metallic ion supply system employing the pelletized metallic compound supply system 400 of FIG. 4, a dilution bypass 412 is provided to the reservoir 10 from the deionizer 14 supplying process water to the reservoir for dilution to the desired dilute concentrate. For an exemplary embodiment, reservoir 10 is a 1000 liter tank and cartridges 404 contain approximately 28.49 cc (or 14.47 cc compressed) of AgNO3 powder. When diluted to the 1000L volume of reservoir 10, a dilute concentrate of approximately 63 ppm is provided. Recirculation of the dilute concentrate by circulation pump 26 through manifold 28 maintains a mixed condition of the dilute concentrate. 1000L storage tank will provide dilute concentrate through manifold 28 for one day to an inlet tunnel on the current largest washer in the world (Milnor CBW 250 lb) with a 3.4L per tunnel injection to dose yielding 1 mg Ag/kg linen (63 ppm AgNO3 provides 40 ppm Ag as the active antimicrobial agent).

Aeration of the concentrate to enhance measurement accuracy with TDS or conductivity probes in the reservoir 10, as previously described, is provided by a diffusion device 414, which may be of comparable structure to the diffusion device 209 described with respect to FIG. 2, in one or more of the bypass line 412, inlet to the rinse head 406 or high ion concentrate inlet 411 to the reservoir 10. The desired aeration induced by the diffusion device is above 100% saturation (relative to published values).

An example integration of the described embodiments into a commercial washing system is described in more detail with reference to FIG. 6 which shows a schematic of an industrial laundry facility. The washing machine may have multiple modules, thereby known as a Continuous Batch Washer (CBW). FIG. 6 depicts an instance where the present invention is integrated into a CBW process. Linens enter the system soiled 601 in batches of several hundred pounds and are transferred 602 manually by plant workers to a conveyor belt 603 that carries them to an elevated height where they are then gravity fed 604 into the CBW. The most effective integration of the present invention into this particular example of an industrial laundry facility is represented in FIG. 6 through placement of the antimicrobial and antimicrobial fluid combination outlet in manifold 28 which the example embodiment uses to inject the antimicrobial agent into the CBW rinse module 636. The example embodiments from FIG. 3 or 5 may be used in connection with water source 12, pressurized air source 235 and the CBW rinse module 636. The water source 12 receives municipal water 606 which is conditioned by a resin based, ion exchange, water softening system 607 and is heated using multiple boilers 608. The water source 12 provides water for the CBW wash modules 605 and delivers water to the system 5 for the embodiment shown. The antimicrobial fluid manifold 28 delivers the antimicrobial agent into the CBW rinse module 636. Once the linens have been treated with the antimicrobial agent in the CBW rinse module 636, they are automatically loaded 611 into a linen press 612, which presses excess rinse water out of the linens. That pressed water is recycled back into the beginning of the CBW system through rinse water recycle line 613. The rinse water recycle line 613 for the embodiment shown reintroduces the antimicrobial agent into the beginning of the wash cycle for added efficacy in antimicrobial treatment of the washed linens. Upon exiting the press 614, the linens may enter dryers or other machines within the laundry facility.

Having now described the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims. 

1. An antimicrobial supply system comprising: a metallic antimicrobial agent supply comprising a metallic antimicrobial agent concentrate supply and an output for the metallic antimicrobial agent concentrate; a dilution reservoir, wherein the dilution reservoir is a bulk reservoir, in fluid connection to the output of the metallic antimicrobial agent supply and having an input from a diluent supply, and wherein the dilution reservoir is configured to form a dilute concentrate from (i) diluent received from the diluent supply via the input of the dilution reservoir and (ii) the metallic antimicrobial agent concentrate received from the metallic antimicrobial agent supply via the output of the metallic antimicrobial agent supply; an output of the dilution reservoir coupled to at least one application system; and an electronics control module connected to (i) a first flow controller between the diluent supply and the dilution reservoir and (ii) a second flow controller between the metallic antimicrobial agent supply and the dilution reservoir, wherein the electronics control module is configured to: control, based on a predetermined metallic antimicrobial agent concentration in the dilute concentrate, the first flow controller and the second flow controller to achieve a desired metallic antimicrobial agent concentration of the dilute concentrate in the dilution reservoir.
 2. The antimicrobial supply system of claim 1, further comprising: a concentration probe in the dilution reservoir and configured to measure the metallic antimicrobial agent concentration of the dilute concentrate in the dilution reservoir.
 3. The antimicrobial supply system of claim 2, wherein the electronics control module is further configured to receive, from the concentration probe, an indication of the metallic antimicrobial agent concentration of the dilute concentrate in the dilution reservoir.
 4. The antimicrobial supply system of claim 3, wherein the electronics control module is connected to a third flow controller that controls the flow of the dilute concentrate to the at least one washing system.
 5. The antimicrobial supply system of claim 2, further comprising a sensor in communication with the electronics control module, wherein the sensor comprises at least one of a temperature sensor, a pressure sensor, an air pressure sensor, or a flow sensor.
 6. The antimicrobial supply system of claim 5, wherein the sensor consists of the temperature sensor.
 7. The antimicrobial supply system of claim 5, wherein the sensor consists of the pressure sensor.
 8. The antimicrobial supply system of claim 5, wherein the sensor consists of the air pressure sensor.
 9. The antimicrobial supply system of claim 5, wherein the sensor consists of the flow sensor.
 10. The antimicrobial supply system of claim 10, wherein the flow sensor senses a flow of the dilute concentrate supplied from the dilution reservoir to a manifold.
 11. The antimicrobial supply system of claim 5, wherein the electronics control module is configured to receive data from the sensor.
 12. The antimicrobial supply system of claim 11, wherein the electronics control module is further configured to log the data received from the sensor.
 13. The antimicrobial supply system of claim 11, wherein the electronics control module is further configured to determine that the data received from the sensor deviates from a parameter associated with the sensor.
 14. The antimicrobial supply system of claim 13, wherein the electronics control module is further configured to, responsive to a determination that the data received from the sensor deviates from the parameter, transmit, via a communication network, an alert signal to a remote system.
 15. The antimicrobial supply system of claim 13, wherein the electronics control module is further configured to: receive, via a communication network, a control signal; and responsive to the control signal, adjust the parameter associated with the sensor.
 16. The antimicrobial supply system of claim 11, wherein the electronics control module is configured to transmit, via a communication network, the data to a remote monitoring system.
 17. The antimicrobial supply system of claim 1, further comprising a manifold coupling the output of the dilution reservoir to the at least one application system. 